Methods of manufacturing a stator core for a brushless motor

Abstract

Method of manufacturing a stator core includes stacking a plurality of substantially T-shaped teeth obtained from a jigsaw pattern of said teeth into a plurality of stacks. In each said stack, said teeth are substantially aligned with each other. Said method includes winding said stacks with a plurality of windings and placing said stacks along the perimeter of a polygonal outer surface of a ferromagnetic tube having an inner channel. Each side of said outer surface corresponds to each said stack and contacts the bases of said legs of each said stack. Said method includes inserting said stacks and said tube into an inner space defined by an annular inner surface of a mold and a shaft into said channel. Said stacks are stationed along the circumference of said inner surface. Said method includes vacuum encapsulating said inner space in epoxy resin and removing said mold and shaft.

What is claimed is: 
     
       1. A method of manufacturing a stator core, said method comprising:
 stacking a plurality of teeth into a plurality of stacks, wherein said teeth are obtained from a jigsaw pattern of said teeth, said teeth are substantially identical to each other in size, each said tooth is substantially T-shaped as defined by two arms protruding sideways from a leg, in each said stack said teeth are substantially aligned with each other; 
 winding said stacks with a plurality of windings; 
 placing said stacks along the perimeter of a polygonal outer surface of a ferromagnetic tube having an inner channel extending therethrough, wherein each side of said outer surface corresponds to each said stack and contacts the bases of said legs of each said stack; 
 inserting said stacks and said tube into an inner space defined by an annular inner surface of a mold and a shaft into said channel, wherein said stacks are stationed along the circumference of said inner surface, the top surfaces of the arms face said inner surface; 
 vacuum encapsulating said inner space in an epoxy resin; and 
 removing said mold and said shaft. 
 
     
     
       2. The method of  claim 1 , wherein said pattern defines at least a portion of a sheet, at least one of said teeth includes a soft magnetic alloy, at least one of said windings is a coil or a belt and each said winding corresponds to each said stack. 
     
     
       3. The method of  claim 2 , wherein said portion is formed by cuffing, said annular inner surface includes a plurality of separators, at least one of said windings is laminated and each said separator is stationed between two of said stacks. 
     
     
       4. The method of  claim 3 , wherein said shaft is connected to a base, said separators extend in parallel along said annular inner surface, said cuffing includes waterjet cuffing. 
     
     
       5. The method of  claim 4 , wherein the outer surface of said mold is polygonal, said mold includes paraffin or aluminum. 
     
     
       6. The method of  claim 5 , wherein said base is connected to said mold, said stacks have a substantially identical height.